The Final RS Door Panel Thread!!

[cegerer]

OK, I've not only searched the Pelican BBS and its many RS Door Panel threads, but all my other references and sources as well. And I still don't have the information I need on early RS door panels (not RS America panels). We really need a comprehensive tech article on installing these. And I'd be happy to put one together once I figure it out myself! In the meantime, this is what I'm looking for:

1. Closeup photos of connection between door strap and opening mechanism.

2. Closeup photos of panel fasteners.

3. Closeup photos of the strap itself.

4. Closeup photos of how the strap is fastened to the door panel.

Preferrably, all of these photos would be from an original 73 RS Lightweight. Maybe somebody can get these photos at Cambria??? Any assistance would be greatly appreciated!! -- Curt

[pwd72s]

Curt, I can offer a lead...a white car I saw at Cambria last year...california plates read REAL RS...white, blue graphics. It may be there again this year, and perhaps Jack or somebody could show up with his camera, get the pics you need? (just hinting a bit here)

[GeorgeK]

Maybe I can help some here.

The leather strap attaches to the same point as the steel rod actuated by the door lever. a 5mm screw&bolt are needed there, and some patience, because you do that blind. It helps if you unscrew the mechanism (3 screws on the shut panel).
You have to cut a rectangular hole in the inner door panel for the strap. I cut it at the level of the attchment of the strapon the mechanism (...) the strap attchment points are at the same height
If you have the turn bezel for the door lock mechanism on the panel, lose it, and put the older style knob.
The handle is still available from the factory.
I used some plastic panel (ABS) and glued vinyl on it. I also paintd the top edge of the inner door shetmetal semi gloss black.
GeorgeK

[cegerer]

Thanks George. A photo is worth a 1000 words.

1) Question on panel fasteners: are they simply chrome phillips-head screws? Do they have a grommet or washer of some sort? Is this same-size screw used to secure the end of the strap handle?

2) Many of the installations I've seen use the standard vinyl-covered 'top rail' (although maybe I'm recalling RS America panels??). You've got the top of the inner sheetmetal exposed and painted. Your detail is correct, I assume?

Thanks, Curt.

[GeorgeK]

Hi Curt,
The fateners are 4 mm allen head crews. There is a cup shaped washer for the conical heads.
Evrey srew is fastened into a threaded rivet, that I put in the door steel sheet.
The screws for the handle and the leather strap fixed end are 1 mm larger diameter. The handle screws are conical heads, the strap is half sphere shaped heads.
The RS lightweight had the vinyl covering the top sheetmetal up to the windows, but I tried it and it looked less neat. I have one screw apparent this way, but it looks tidier. Not "correct in the factory historical way", but neat.
BTW the inner door panels were painte semi gloss black on the '73 RS, that is correct.
GeorgeK

[cegerer]

Excellent! Thanks George. -- Curt

[Rich911E]

That is a really nice job George.

Could you say how large the rectangular hole is and whether you used a grommet as it passes through the fabric? Additionally, what is the source for the little door handle/pull? Is it a Porsche or VW part?

This is definitely a "this weekend" project this week for me -- I'm sick of looking at my half complete door panel (ie. missing pocket).

Thanks

Rich

[cegerer]

Rich, my panels have the rectangular hole and are 2cm wide by 2.5cm high. The center of this rectangular hole is 22cm from the top panel edge and 7cm from the panel's rear edge.

I'm also wondering if the strap material is the same as the 'luggage straps' available for the rear jump seats - they sure look similar! -- Curt

[GeorgeK]

The handle is a Porsche part, actually the same as on the '73 RS, and the 964 Cup ars. It is still available. doa search, the part number has been mentionned a few times.
the leather is indeed the same quality as the luggage strap or the rear backrest straps leather
GeorgeK

[cegerer]

Got my RS door handles today (#901.531.067.00 - $18.36 each from Stoddard). Wow, are these things flimsy!!! But they are light. And that's what counts, right?

Also, Stoddard sells packs of phillips-head door panel screws and cup-shaped washers for pre-68 (I think) door panels that have exposed screws. I figure these are the same as that used on the 73RS, or very close. They look like stainless steel. Part number is #SIC.555.001.00. $5.55 for a pack of about 10-12. -- Curt

PS: I think I found the least-expensive official Porsche part in existance. It's #999.591.384.40. A single cap for the plastic Targa bar plugs. $0.31 each.

[CamB]

I think I read somewhere that the handle is a Fiat Bambina or Tupolino part. Now if only I can remember where??

[cegerer]

It is Fiat and still 'Made in Italy'. -- Curt

[cegerer]

Here's a small tip that might save you some headaches. There are 3 screws along the bottom edge of an RS door panel. The center screw is located at a bolt plate for the old door pocket hinges. These must be removed. Look inside the door cavity and you'll see it. There's a rectangular piece of steel with 2 threaded holes; it's held to the back of the door with a piece of sheetmetal spot-welded to the door. Just pry this off. Also, you might want to put a dab of silicone on the other bolt plates so the plates don't rattle around while you're driving. -- Curt

[cegerer]

I came across these door panels for sale on the German RSL website. I've never seen this arrangement with the door strap attached directly to the door pull handle???

[steveW]

HOT TIP OF THE CENTURY

Instead of using a 5mm nut and bolt to attach the strap to the door lock mechanism, I used a piece of wire - I tried a nut and bolt, but gave up after swearing a lot. I wrapped the wire with some foam to stop it rattling against the door metal!

[cegerer]

The wire sounds like a good solution. I used a clevis pin. Had to cut it down in length and re-drill the hole:

[rw7810]

I finally got my panels made. Not at all hard. Took time finding the parts, but overall an easy job. See pic.

[cegerer]

Nice job! I guess since I started this thread, I should post a pic of my panels after installation:



BTW, if anyone is having trouble finding the correct leather for the pull strap, I found a source. Rhode's Leather Shop in Bridgeport, Michigan. These guys are one of a handful of old-time leathersmiths left in the country. They made up some straps for me that are very close to the originals for under $15! -- Curt

[Want to be]

Yes please post where in Michigan you ordered the leather straps.

Does the leather straps have holes punched in them?

Quesiton: Where can i get the ABS plastic for the door panels?

Or can i just use the orginal panel and recover it ?

I have installed an RS America panel before but the door mech's seem different than my carrera i once owned. I currently have a 1968 912 with push button not a handle. Can i still install your early style RS door panels?

I have written down the part numbers for the screws and handle but i am now stumped on the leather strap (unless i use a few of my wife brighten purses) NOT!!!!!!

I am in the process of recovering my entire car black instead of red.

My car is missing the pockets and i can not see myself buying the over priced door pockets.

Thanks for any help

jpc

[cegerer]

Rhode's Leather Shop is at 989-777-2340. They will probably remember doing mine back in May. What you'll need is 7/8 inch wide by about 1/8 inch thick leather strapping. It will be black on one side and natural on the edges and back. I had them color/dye the edges black. They will put slight embossing lines along the edges similar to the straps for your rear seat hold downs. You need two 24 inch long pieces. I had them put a 3/8 inch or so (inside diameter) brass grommet in one end of each strap (for attachment to the opening mechanism). The other end you'll cut to length after installation and screw into the door metal.

I think the strap will work the same way for you even with the push button door handles. I don't know about the backerboard, I bought mine finished. But there have been other threads regarding that. Good luck. -- Curt